Collapsible construction module

ABSTRACT

Systems and methods of using a collapsible construction module are described. The module may include an internal framework having horizontal support bars and masts pivotably attached to the horizontal support bars. The module may further include vertical support bars fixed to the horizontal support bars. Beams may be connected to ends of the support bars. The module may orient between open and closed positions by pivotably rotating the masts independent of the beams.

FIELD

The disclosure relates generally to modular construction elements or racks and, more particularly, to modules or racks capable of being used in a wide range of applications including construction, reinforcement of structures, and drilling rigs.

BACKGROUND

Buildings and other various structures of all shapes and sizes are constructed every day. Each of these buildings may have a unique layout with specifically sized locations. Thus, there is a need for a construction module capable of being easily transported to the construction site and capable of being easily implemented within the construction site.

SUMMARY

An aspect of the present disclosure relates to a construction module or rack that can be expanded and contracted. In a contracted position, the module can be transported from and to various location rather easily. The construction module may include an internal framework having horizontal support bars and masts attached to the horizontal support bars, vertical support bars fixed to the horizontal supports, and beams connected to the support bars. This disclosure also includes methods for using such modules or racks in building and constructing structures. In an embodiment, the length of the module may be about 15 feet, and may fit on a vehicle, such as a truck, for example. In certain embodiments, the construction module allows pipes and wiring to be threaded or fed therethough.

In another aspect, the construction module that can be folded and unfolded has an internal framework having at least four horizontal support bars. The at least four masts each are pivotally attached to one of the horizontal support bars on each end and each mast pivots in the horizontal plane. At least four vertical support bars are fixed to the horizontal supports, and a number of beams connected to the ends of the support bars. A first beam end is contactable to the support bars and can pivot independent of the masts. The masts are substantially parallel to each other and perpendicular to the support bars when the module is unfolded, and the masts the substantially parallel when the module is folded.

The construction modules can be stored more conveniently on a site or offsite. For instance, by folding or collapsing the modules, the modules may be stacked upon one another. The construction modules may be used in a wide variety of operations. For example, the modules may be used at drilling sites. The modules may also be used in applications where traditional modules or racks are used.

Additional features and advantages of the present disclosure are described below. This disclosure may be readily utilized as a basis for modifying or designing other structures, systems, and processes for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent implementations do not depart from the teachings of the disclosure as set forth in the appended claims. The novel features, which are believed to be characteristic of the disclosure, both as to its organization and method of operation, together with further objects and advantages, will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The particular features and advantages of the present disclosure will be apparent from the detailed description set forth below in conjunction with the drawings in which like reference characters identify corresponding aspects throughout.

FIG. 1A is a prospective view of a collapsible construction module according to the present disclosure.

FIG. 1B is a prospective view of the collapsible construction module according to the present disclosure.

FIG. 2 is a side view of the collapsible construction module according to the present disclosure.

FIG. 3 is a side view of the collapsible construction module according to the present disclosure.

FIG. 4A is a prospective view of a strut of the collapsible construction module according to the present disclosure.

FIG. 4B is an expanded view of an end of the strut of the collapsible construction module according to the present disclosure.

FIG. 4C is an elevated side view of the strut of the collapsible construction module according to the present disclosure.

FIG. 4D is a top view of the strut of the collapsible construction module according to the present disclosure.

FIG. 4E is a prospective top view of the strut of the collapsible construction module according to the present disclosure.

FIG. 5 is a flow diagram of folding the collapsible construction module according to the present disclosure.

FIG. 6 is a flow diagram of unfolding the collapsible construction module according to the present disclosure.

DETAILED DESCRIPTION

The detailed description set forth herein makes reference to the accompanying drawings, which show various aspects of the present disclosure by way of illustration. While these various aspects are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments and implementations may be realized and that logical and mechanical changes may be made without departing from the scope of the disclosure. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not limited to the order presented. Moreover, references to a singular embodiment may include plural embodiments, and references to more than one component may include a singular embodiment, for example.

According to an aspect of the present disclosure, a collapsible construction module (“module”) 100 is described with reference to FIGS. 1A-3. The module 100 may include an internal framework having horizontal support bars 102 and masts 104, vertical support bars 106, beams 108, struts 110, and brackets 112

In an embodiment, the internal framework may include at least four horizontal support bars 102 and at least four masts 104. A side of each horizontal support bar 102 may be pivotably attached to ends of multiple masts 104. In another embodiment, the internal framework may include four horizontal support bars 102 and four masts 104, with each of the masts 104 being pivotably attached proximate to or at ends of the horizontal support bars 102. In a further embodiment, the internal framework includes four horizontal support bars 102 and at least four masts 104 pivotably attached to the horizontal support bars 102. The internal framework may be configured to have two parallel or substantially parallel sections: each including two horizontal support bars 102 pivotably connected to at least two masts 104.

In an illustrative embodiment, ends of the masts 104 may be pivotably attached to sides of the horizontal support bars 102. This may include using one or more brackets attached to the sides of the horizontal support bars 102 whereby the ends of the masts 104 pivotably attach directly to the brackets. The brackets may be permanently or removably attached to the horizontal support bars 102 using, for example, welding, epoxy, and/or mechanical fasteners such as screws or bolts. The masts 104 may contain holes located through opposing sides of the masts 104 that align with holes located through opposing sides of the brackets. When attached, the opposing sides of the brackets may fit within the opposing sides of the masts 104 having the holes located therethrough or the opposing sides of the brackets may abut the exterior of the opposing sides of the masts 104 having the holes located therethrough. Pivotable attachment of the masts 104 to the brackets may include fasteners, such as pins, bolts, screws, or any other fastener sufficient to provide operable pivotable attachment.

In another illustrative embodiment, the masts 104 may attach directly to the horizontal support bars 102 without the use of brackets. The horizontal support bars 102 may have holes located through opposing sides of the horizontal support bars 102. The masts 104, which may have two pairs of opposing sides, may have holes located through a first pair of opposing sides and indents cut into a second pair of opposing sides. The indents allow the first pair of opposing sides to fit around the horizontal support bars 102, resulting in an alignment of the holes located in the horizontal support bars 102 and the masts 104. Pivotable attachment of the masts 104 to the horizontal support bars 102 may include fasteners, such as pins, bolts, screws, or any other fastener sufficient to provide operable pivotable attachment.

When the module 100 is in an open/unfolded position, the masts 104 may be parallel or substantially parallel to each other and perpendicular or substantially perpendicular to the horizontal support bars 102. When the module 100 is in a closed/folded position, the masts 104 may be substantially parallel with each other and more parallel with respect to the horizontal support bars 102 compared to when the module 100 is in the open/unfolded position. In an embodiment, the internal framework may be rectangular when the module 100 is in the open/unfolded position. However, it should be appreciated that the internal framework may form other shapes when the module 100 is in the open/unfolded position, such as a parallelogram, for example. In a folded position, construction module may be relatively flat and may be stacked one over the other.

The vertical support bars 106 may be attached to the horizontal support bars 102. This attachment may occur through a variety of means, such as welding, epoxy, and/or mechanical fasteners, for example, and may also include the use of brackets permanently or removably attached to one or both of the horizontal support bars 102 and the vertical support bars 106. Mechanical fasteners may include, for example, bolts, screws, and pins. In an embodiment, the vertical support bars 106 attach along the horizontal support bars 102 at regular intervals. However, the vertical support bars 106 may be attached to the horizontal support bars 102 at irregular intervals without departing from the scope of this disclosure. Further, the vertical support bars 106 may attach to the horizontal support bars 102 in plane with the masts 104.

In an illustrative embodiment, at least four vertical support bars 106 are fixed to the horizontal support bars 102. In another embodiment, the vertical support bars 106 may be attached to the horizontal support bars 102 proximate ends of the horizontal support bars 102, thereby adding additional structural support near the attachment locations of the horizontal support bars 102 and the beams 108, described below. The vertical support bars 106 may further be attached to the horizontal support bars 106 such that the vertical support bars 106 remain in a single configuration/orientation with respect to the horizontal support bars 102 whether the module 100 is in the open/unfolded or closed/folded position. In yet another embodiment, the vertical support bars 106 may have equal or substantially equal lengths thereby orienting the two sections of the internal framework, detailed above, to be parallel or substantially parallel with each other.

The beams 108 may be connected to ends of the horizontal support bars 102 and/or attached to the vertical support bars 106 located proximate or at ends of the horizontal support bars 102 (i.e., ends of the module 100). Such attachment of the beams 108 to the vertical support bars 106 may occur at or proximate ends of the vertical support bars 106, or may occur at locations distant from the ends of the vertical support bars 106.

In an illustrative embodiment, there may be three beams 108 at each of the two ends of the module 100. The three beams 108 may have a U-shaped configuration whereby a first beam 108 is equal to or substantially equal to the length of the vertical support bars 106 and the other two beams 108, each being attached to the first beam 108, may be equal to or substantially equal to the length of the masts 104. The two beams 108 may be attached to the first beam 108 at ends of the first beam 108 and/or ends of the two beams 108, or distant from ends of the first beam 108 and/or ends of the two beams 108. The first beam 108 may be permanently or removably attached to the other two beams 108 by welding, epoxy, and/or mechanical fasteners, for example. Ends of the two beams 108 distal from the first beam 108 may be pivotably, and in some embodiments removably, attached to the horizontal support bars 102 and/or vertical support bars 106 by fasteners, such as bolts, screws, and pins, for example. This attachment may include the use of brackets permanently or removably attached to the horizontal and/or vertical support bars 102 and 106. The first beam 108 may be removably attached to ends of the horizontal support bars 102 and/or a vertical support bar 106 located proximate to or at ends of the horizontal support bars 102. Such removable attachment of the first beam 108 may occur using, for example, magnets, bolts, screw, pins, or the like. In an additional embodiment, the removable attachment of the first beam 108 allows the beams 108 to pivot independently of the masts 104 when the module 100 is oriented from the closed/folded position to the open/unfolded position, and vice versa. In yet another embodiment, the beams 108 may be configured to stop the masts 104 from pivoting about the horizontal support bars 102. Such configuring may be dictated by the size and/or shape of the beams 108, for example.

Struts 110 may be attached to the masts 104 and vertical support bars 106, as described with reference to FIGS. 1A, 1B, and 3. The struts 110 may have longer portions attached to the vertical support bars 106 and shorter portions attached to the masts 104. However, the longer portions may be attached to the masts 104 and the shorter portions may be attached to the vertical support bars 106 without departing from the scope of this disclosure. Attachment of the struts 110 permanently or removably to the masts 104 and vertical support bars 106 may include using welding, epoxy, and/or mechanical fasteners such as bolts, screws, and pins, for example.

Brackets 112 may be attached to the horizontal support bars 102 to provide a connection point whereby the module 100 may be removably or permanently attached to a site. The brackets 112 may be attached to the horizontal support bars 102 using welding, epoxy, or mechanical fasteners, for example. In an embodiment, the brackets 112 may have one or more holes drilled therethrough that allows use of one or more mechanical fasteners, for example a screw or bolt, to be used to fasten the module 100 to the site.

The module 100 may form a parallelogram while in the open/unfolded position. However, it should be appreciated that the module 100 may form other shapes while in the open/unfolded position, such as a square or box, for example. Additionally, the module 100 may be configured to be relatively or substantially flat while in the closed/folded position. The module 100 may further be configured to be stackable with other modules 100 while in the open/unfolded and/or closed/folded positions. The module 100 may also be configured to have a length of 15 feet while in the open/unfolded and/or closed/folded positions. However, it should be appreciated that other lengths of the module 100 may be achieved without departing from the scope of the present disclosure. Such length of the module 100 may depend upon the type or location of the site where it is to be installed, and/or the method of delivery (i.e., type of vehicle transporting the module 100), for example. Additionally, the module 100 may be configured to permit, for example, pipes and wiring, to be threaded or fed through it. The module 100 may be composed of one or more of various metals, metal alloys, or any other type of material having sufficient structural capabilities to perform the functions described herein. In certain examples, the modules allow pipes and wiring threaded or fed therethrough in, e.g., the longitudinal direction.

With reference to FIGS. 4A-4E, various embodiments of the strut 110 are described. The strut 110 may include a long side 402 permanently or removably attached to a short side 404 using welding, epoxy, and/or mechanical fasteners, for example. In an embodiment, the long and short sides 402 and 404 may have grooves 410 located along the long and short sides 402 and 404 for increased structural support. In another embodiment, the long and short side 402 and 404 may have U-shaped configurations for increased structural support.

In an illustrative embodiment, brackets 406 may be permanently or removably attached to ends of the long and short sides 402 and 404 using, for example, welding, epoxy, and/or mechanical fasteners. The brackets 406 may be used to attach the strut 110 to the masts 104 and vertical support bars 106. However, it should be appreciated that the long and short sides 402 and 404 of the strut 110 may permanently and/or removably attached directly to the masts 104 and vertical support bars 106 without the use of the brackets 406. In an embodiment, the brackets 406 may have holes 408 located therethrough. The holes 408 may be centrally or off-centrally located through the brackets 406.

A method 500 of folding a module according to embodiments of the present disclosure is described with reference to FIG. 5. At block 502 the aforementioned first beam is detached from the support bars. At block 504 the masts are pivoted so they become parallel or substantially parallel. At block 506 the detached first beam is rested upon the folded module, which is relatively flat when folded.

A method 600 of unfolding a module according to embodiments of the present disclosure is described with reference to FIG. 6. At block 602 an unattached first beam is removed from a resting position upon the folded module. At block 604 the masts are pivoted so they become perpendicular or substantially perpendicular to the horizontal support bars. At block 606 the first beam is attached to the supports, thereby completing the unfolded module.

The structures described herein can be designed to meet strength and dynamic requirements, while reducing the need to increase the material added to the structure to satisfy deflection requirements. The structures described above are also lighter and cheaper than existing comparable structures.

The present disclosure is in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims. 

What is claimed is:
 1. A construction module that can be folded and unfolded, comprising: an internal framework having at least four horizontal support bars; at least four masts each pivotally attached to one of the horizontal support bars on each end; wherein each mast pivots in the horizontal plane; at least four vertical support bars fixed to the horizontal supports; a number of beams connected to the ends of the support bars, wherein a first beam end is contactable to the support bars and can pivot independent of the masts; wherein the masts are substantially parallel to each other and perpendicular to the support bars when the module is unfolded; and the masts the substantially parallel when the module is folded.
 2. The module as claimed in claim 1, wherein the module is about 15 feet.
 3. The module as claimed in claim 1, wherein the modules allow pipes and wiring threaded or fed therethrough in the longitudinal direction.
 4. The module as claimed in claim 1, wherein the beams stop the pivoting of the masts about the horizontal support bars.
 5. The module as claimed in claim 1, wherein construction module is relatively flat when folded.
 6. The module as claimed in claim 1, wherein the construction module is box-shaped when unfolded.
 7. A stackable system of construction modules wherein each of the construction module can be folded and unfolded, comprising: an internal framework having at least four horizontal support bars; at least four masts each pivotally attached to one of the horizontal support bars on each end; wherein each mast pivots in the horizontal plane; at least four vertical support bars fixed to the horizontal supports; a number of beams connected to the ends of the support bars, wherein a first beam end is contactable to the support bars and can pivot independent of the masts; wherein the masts are substantially parallel to each other and perpendicular to the support bars when the module is unfolded; and the masts the substantially parallel when the module is folded.
 8. The system as claimed in claim 1, wherein the construction modules can be stacked. 